Method and apparatus for lining process tanks

ABSTRACT

A method and apparatus for lining process tanks. The method comprises lining a tank with a plurality of sheets, wherein the tank has walls and a bottom that intersect at a corner of the tank. The method comprises bonding a bottom sheet of the plurality of sheets to the bottom of the tank. Next, a pair of sheets of the plurality of sheets are bonded to adjacent walls of the tank and above the bottom sheet, each sheet of the pair of sheets having a first edge and a second edge such that the first edges of the pair of sheets are positioned at the intersection of adjacent walls of the tank to position an interface between the pair of sheets. The method also comprises extrusion welding the pair of sheets together by infusing a molten thermoplastic material along the pair of sheets and within the interface of the pair of sheets. Additionally, the method comprises extrusion welding the pair of sheets to the bottom sheet by infusing the molten thermoplastic material along and between the pair of sheets and the bottom sheet wherein the infused thermoplastic material seals the pair of sheets and bottom sheet to isolate the tank from contents that contact the pair of sheets and bottom sheet.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND OF THE DISCLOSURE

The present disclosure relates to a method of lining a process tank, andin particular, the present disclosure relates to lining a process tankusing sheets that are extrusion welded together by infusing moltenthermoplastic material within the interfaces of adjacent sheets. Thepresent disclosure also relates to a resultant lining formed by thewelded sheets and infused material. For descriptive purposes, the term“liner” and “lining” are used interchangeably.

Currently, contents such as acids and chemicals are stored in tanksusually in the form of process tanks. These tanks relate to immobiletypes that may be installed above or below the ground, but also for thetransportable types that are part of the over-the-road semi-trailers.The tanks may also be used on or in marine vessels as well as railroadcars. The size of the tank is not material, but the large tankstypically hold 1,000 gallons or more. Moreover, process tanks areparticularly adaptable for tanks intended for highly corrosive liquids,but also may be used in conjunction with other pourable materials suchas grain and pellets.

Most process tanks of the type considered are steel tanks which, over aperiod of time, may become corroded as a result of the fluids storedtherein, or because of the rusting action of the exterior elements(ground water, rain, etc.). If the material stored in such tanks iscorrosive, the corrosive material can contact the tank. In thissituation, the life expectancy of the tank is relatively short and thusit becomes not only extremely expensive for replacement, but also highlydangerous for people and the environment. Furthermore, there is dangerin the event that the tanks leak or are ruptured, or somehow fail toretain the contents and leak the contents into the ground (if the tanksare subterranean). If they are above-the-ground storage tanks, or to thepassing public if the tanks are over-the-road type, there is dangeralong the highways and to the passing public. Accordingly, many processtanks utilize a protective liner or lining.

One common type of liner is a pre-fabricated “drop-in” liner. Whiledrop-in liners may be machine welded (radio frequency welding iscommonly used for these liners), the drop-in liners have disadvantageswith respect to a bonded lining. During the drop-in process, air isentrapped behind the liner, which can condense and cause the mild steeltank to rust. Furthermore, during the drop-in process, creases form inthe liner sheet, which stresses the liner material and leads topremature cracking and failure. Additionally, a tank part may catch thecrease or protruding wrinkle and cause tear damage to the drop-in liner.When the drop-in liner develops a leak, solution seeps behind the linerpushing it off the walls or bottom and causing the liner itself to moveinto the process tank area resulting in operational problems. Oncesolution is behind a drop-in liner, the liner is very difficult torepair, since it may be almost impossible to find the source of theleak. Replacing the drop-in liner creates significant downtime,especially for electroplating tanks with auxiliary equipment affixed tothe tank rim, i.e., ventilation hoods, piping, anode and cathode bars,heat exchangers and probes, level control devices, etc

Another common liner is a bonded to metal lining. As will be discussed,this liner uses manual “flat strip” welds on the butted side panels and“corner strip” welds on the vertical joining walls and side to bottomjoints.

In current lining procedures, installation personnel prepare theinterior of the surface of the tank 10 (FIG. 1) to receive the liner 14.This preparation includes surface blasting the interior of the tank 10and subsequent cleaning of the interior of the tank 10.

With respect to the liner 14, the installer cuts sheets of liner 16(FIG. 2) from a roll of liner material. At the installation site, theinstaller applies an adhesive to the now cut sheets of liner 16. Then,the installer manually applies the liner sheets 16 to the interior ofthe tank 10. As known in the art, heat may be applied to the linersheets 16 to assist in applying the liner sheets 16 to the tank wall.Tanks typically have protrusions such as tank welds that bond the tankwalls to the tank bottom. These tank welds protrude into the interior ofthe tank. Even careful placement of the sheets 16 will result in gapsbetween the sheets 16 that are placed over the protruding welds. Inother words, the sheets 16 will lay over the protrusions furtherenhancing the gaps between the sheets 16.

As shown in FIG. 2, current cutting procedures result in uneven and/orrough edges 18 for each liner sheet 16. When the installer adheres theliner sheets 16 to the tank 10 and next to each other, the rough edges18 of the liner sheets 16 do not evenly match resulting in gaps 20forming between the sheets 16. When the installer cuts relatively smoothedges 18, installation gaps 20 still exist between the adjacent linersheets 16 due to the difficult and labor intensive installation process(FIG. 3). For example, the liner sheets are heavy and difficult tomanage as the installer handles the sheets while positioned within thetight constraints of the process tank, i.e., a confined space withelevated temperatures. As such, the installer may apply adjacent sheets16 in a non-uniform layout and/or with a distance between them, furtherenhancing the gaps 20 between the edges 18 of the sheets 16. Applyingthe sheets at a corner of the tank 10 is particularly troublesome due tothe space and angle considerations of the corner of the tank 10.

After applying the liner sheets 16, the installer welds a weld strip 22(known as a “cap over flat strip weld” or a “cap over corner stripweld”) along the interface between a pair of adjacent sheets 16 (FIGS. 2and 3). The installer manually welds the weld strip 22 to the adjacentliner sheets 16. The welders used in this process heat the weld strip 22to the liner sheets 16. Similar to the application of the liner sheets16, hand welding the weld strips 22 is a labor-intensive process.Maintaining consistent pressure with the welder is difficult since thetouch of the installer applies the pressure. Additionally, it isdifficult with the hand welder to maintain a constant distance betweenthe welding nozzle and the welding strip. Furthermore, the weld stripmay melt faster than the liner sheet, so the welding process must bedone with special care. The sheets must be heated to a glossy state, yetthe weld strip or the sheets cannot be charred, as that would result ina failed weld.

The installer typically welds from the top of the liner sheet 16 to thebottom. As the process tank may have a height such as twelve feet, thisheight causes starts and stops as opposed to continuous welds withtightly controlled temperatures and consistency in both pressure andtiming. In addition, welding occurs within the tight constraints of theprocess tank such that the installer does not provide a constant weldover any length of time. The tedious and laborious process for stripwelding not only applies to welding strips to corner sheets; but also,applies to welding strips for sheets applied to the walls of the processtank 10.

The human element of welding the strips 22 leads to weak welds (i.e.,inconsistency of temperature, pressure and timing—the critical variablesfor welds) and leads to voids or “pinholes” 24 within the weld thatbonds the weld strip 22 to the liner sheets 16 (FIG. 4). The pinholes 24shown in FIG. 4 are exaggerated for purposes of clarity. Although thewelded strip 22 may pass a “spark test” commonly used in the art, thesepinholes 24 lead to problems for the process tank 10 as will bediscussed. Furthermore, the corner weld that bonds sides and the bottomof the process tank further exaggerates the effects of the gaps 20 andthe pinholes 24 since the liner sheet 16 must position over the cornerweld of the process tank 10. This corner weld or other obstacle leaves avoid between the sheet 16 and the tank weld.

When the tank 10 is filled with fluid 12 (FIG. 1) such as an acid, thepressure of the fluid forces the fluid through the pinholes 24.Consequently, the fluid forces through the gaps 20 and disperses betweenthe liner 14 and the tank 10. This leaked fluid then corrosively attacksthe tank wall. Additionally, this leaked fluid may also corrosivelyattack the adhesive interface between the liner 14 and the tank wallresulting in the liner 14 pulling away from the tank wall. Accordingly,the gaps 20 and the pinholes 24 between the liner sheets 16 lead toadverse and dangerous conditions. When the installer repairs the weldedstrip, the heat from the repair welder draws the leaked fluid toward theinterface of the adjacent liner sheets, wherein this fluid furtherattacks the tank wall positioned behind the repaired weld strip.

Process tanks with bonded linings require a lining that eliminates gapsbetween edges of adjacent liner sheets. Process tanks also requiremachine quality consistent strong welds created with consistentpressure, temperature and timing that effectively seals the tank fromthe contents that contact the liner.

The foregoing and other objects, features, and advantages of thedisclosure as well as presently preferred embodiments thereof willbecome more apparent from the reading of the following description inconnection with the accompanying drawings.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure relates to a method of lining a tank with aplurality of sheets. The tank has walls and a bottom that intersect at acorner of the tank. The method comprises bonding a bottom sheet of theplurality of sheets to the bottom of the tank. The method also comprisesbonding a pair of sheets of the plurality of sheets to adjacent walls ofthe tank and above the bottom sheet, each sheet of the pair of sheetshaving a first edge and a second edge such that the first edges of thepair of sheets are positioned at the intersection of adjacent walls ofthe tank to position an interface between the pair of sheets. The pairof sheets is then extrusion welded together by infusing a moltenthermoplastic material along the pair of sheets and within the interfaceof the pair of sheets. Additionally, the method comprises extrusionwelding the pair of sheets to the bottom sheet by infusing the moltenthermoplastic material along and between the pair of sheets and thebottom sheet wherein the infused thermoplastic material seals the pairof sheets and bottom sheet to isolate the tank from contents thatcontact the pair of sheets and bottom sheet.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the accompanying drawings which form part of the specification:

FIG. 1 is a front elevational view of a storage tank having a partialcross sectional view illustrating a current bonded lining applied to thetank walls, and a fluid stored therein wherein the fluid has seepedthrough the liner and is positioned between the tank walls and theliner;

FIG. 2 is a partial perspective view of a corner of a current liningillustrating a pair of liner sheets, a welded strip weld positionedbetween the pair of liner sheets and gaps positioned between the linersheets;

FIG. 3 is a partial perspective view of a corner of another currentlining illustrating a pair of liner sheets having smooth edges, a weldedstrip weld positioned between the pair of liner sheets and a gapposition between the length of the liner sheets;

FIG. 4 is a front perspective of the liner sheets, weld strip and gapsof FIG. 3 and further illustrating pinholes formed in the weld thatbonds the weld strip to the liner sheets;

FIG. 5 is a partial sectional front view of a lining constructed inaccordance with and embodying the present disclosure disposed within atank;

FIG. 6 is a back perspective view of an embodiment of a pair of linersheets constructed in accordance with and embodying the presentdisclosure;

FIG. 7 is a plan view of the pair of liner sheets of FIG. 6 contactingeach other to form a corner beveled region;

FIG. 8 is a plan view of a pair of butt welded side sheets constructedon a sheet butt welding machine in accordance with and embodying thepresent disclosure;

FIG. 9 is a plan view of a pair of extrusion welded side sheetsconstructed in accordance with and embodying the present disclosure;

FIG. 10 is a partial perspective view of an infused weld of the presentdisclosure being applied to the corner of the lining;

FIG. 11 is a front perspective of the pair of liner sheets andassociated infused weld of FIG. 10 constructed in accordance with andembodying the present disclosure;

FIG. 12 is a back perspective view of the contacting pair of linersheets of FIG. 10 further illustrating an infused weld constructed inaccordance with and embodying the present disclosure wherein the infusedweld joins the pair of liner sheets;

FIG. 13 is a plan view of the infused welded pair of liner sheets ofFIG. 12;

FIG. 14 is a plan view of an infused weld of the present disclosurewherein a portion of the infused weld extends beyond the beveled regionsof the pair of liner sheets wherein this portion of the weld isexaggerated for purposes of clarity;

FIG. 15 is front view of a corner insert constructed in accordance withand embodying the present disclosure;

FIG. 16 is a partial perspective view of the insert of FIG. 15 welded toa corner of the lining;

FIG. 17 is a perspective view of a lining constructed in accordance withand embodying the present disclosure;

FIG. 18 is a partial side view of another embodiment of the presentdisclosure illustrating a sacrificial layer and an intermediate layerbonded to a lining;

FIG. 19 is a front prospective view of an embodiment of the lining ofthe present disclosure illustrating the sacrificial layer andintermediate layer bonded to the lining;

FIG. 20 is a partial side elevational view of another embodiment of thepresent disclosure illustrating the sacrificial layer of FIG. 18 bondedto the lining;

FIG. 21 is a front prospective view of an embodiment of the lining ofthe present disclosure illustrating the sacrificial layer of FIG. 20bonded to the liner; and

FIG. 22 is a flowchart illustrating welding steps in accordance with andembodying the present disclosure.

Corresponding reference numerals indicate corresponding parts throughoutthe several figures of the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The following detailed description illustrates the disclosure by way ofexample and not by way of limitation. The description clearly enablesone skilled in the art to make and use the disclosure, describes severalembodiments, adaptations, variations, alternatives, and uses of thedisclosure, including what is presently believed to be the best mode ofcarrying out the disclosure.

Referring to FIGS. 5-21, the present disclosure relates to forming alining 26 and applying the lining 26 to a tank 28 (FIG. 5). As shown,the tank 28 has walls 30, a bottom 32 and a top 34, wherein the walls 30and bottom 32 intersect at corners 36 of the tank 28. The tank 28 mayalso include a cover (not shown) and other components (not shown) suchas a manhole access, access doors and supply/drain valves. Prior toapplying the lining 26 of the present disclosure, installation personnelform the lining 26 and prepare the tank 28.

For the surface preparation of the tank 28, the material shall be freefrom physical imperfections and all sharp edges on the interior of thetank 28 shall be ground smooth. The thickness and weight per square footshall be within the ASTM and AISI tolerances. Furthermore, any weldedparts of the tank 28 shall be fabricated in accordance with standardizedcommercial practice to obtain a practical and uniform quality.Rectangular open tanks, in particular, shall be properly reinforced withgirth angles in accordance with accepted practice in order to provideadequate structural strength and prevent bulging. If welding is requiredon inside corners, the welds must be smooth with no porosity, high spotlumps or pockets. The size construction and location of outlets,openings and/or valve sleeves shall be fabricated in accordance withstandardized commercial practice.

During preparation, the installer removes any sharp edges on theinterior surface. The installer then prepares the interior of thesurface of the tank 28. In doing so, the installer blasts or grinds theinterior of the tank 28 to be free from oil, grease and chemicals. Theinstaller may grit blast steel to a white metal finish in accordancewith steel structures and painting standards. The installer may alsoclean the surface by using steam-cleaning procedures. All rusts, scaleand dirt are removed during the cleaning process. After blasting orgrinding, brushing or vacuuming removes all remaining debris.Furthermore, the installer may apply a primer to prevent oxidation ofany metal surfaces.

With respect to the lining 26, the installer processes a plurality ofsheets 38 (FIGS. 6 and 7) that eventually form the lining. The installermay process the plurality of sheets 38 at the location of the tank 28 bycutting the sheets from a roll of liner material. The installer may alsoprocess the plurality of sheets 38 from the roll of liner material at anoffsite location. The roll of liner material for the liner 26 comprisesan extruded plasticized polyvinyl chloride sheet membrane. One suchliner material is sold under the brand name “Koroseal®” or “HighPerformance Koroseal®” manufactured by R.J.F. International Corporation.Other liner materials for the liner 26 include “Amer-Plate®” or“T-Lock®” or “Arrow-Lock®” from Ameron Protective Linings or “Exceline”from F.C. Witt Associates Ltd.

During the cutting process, the installer pulls a portion of the linermaterial from the roll and places the portion over a cutting surface. Inone embodiment, the height of the liner material is about eight to aboutten feet and the width is about four to about eight feet. Once theproper size of the length of the liner sheet 38 is determined and pulledfrom the roll of liner material, the installer then cuts off the portionfrom the roll material to form the plurality of sheets 38 (FIGS. 6 and7) of liner material. In one embodiment, the plurality of sheets 38comprises a rectangular configuration. The installer cuts the pluralityof sheets 38 in dimensions for use on the walls 30 and the bottom 32 ofthe tank 28 (FIG. 1). These cut sheets are designated as corner pairs ofsheets 40 (FIGS. 6 and 7), side sheets 42 (FIGS. 8 and 9) and bottomsheets 44 (FIG. 10). The lengths and configurations for the bottomsheets 44 are cut according to the respective bottom surface of the tank28 to which the liner 26 is being applied. The plurality of sheets 38may contract and expand slightly in width during installation operationsand during use (i.e., thermal expansion and contraction). Allowance forsuch dimension changes is made when cutting the plurality of sheets 38.The installer typically manually cuts the sheets 38 from the roll ofliner material. In one embodiment, the thickness of the plurality ofsheets 38 is at least 3/32 inches. In another embodiment, the thicknessof the plurality of sheets 38 is about 3/16 inches.

As shown in FIGS. 6 and 7, each corner sheet 40 of the plurality ofsheets 38 has a first edge 46, a second edge 48, a top edge 50 and abottom edge 52. The installer separates the corner pair of sheets 40 sothat the installer may further process the first edge 46 of each sheet40. The installer first processes, i.e. cuts or scrapes, the first edge46 of each sheet 40 in order to clear the edge from uneven surfaces.Next, the installer may then bevel the first edge 46. The installer usesa cutting apparatus to bevel the edges 46 at an acute angle. In oneembodiment, the installer bevels the first edge 46 at about a 45° angle.The installer then processes, such as by cutting or grinding, the secondedge 48 of the sheets 40 in a substantially straight configuration inorder to remove any uneven surfaces. The installer may also bevel thesecond edge 48 of the sheets 40. In one embodiment, the installer bevelsthese edges 48 at about a 45° angle. The installer may also bevel theedges of the bottom sheet 44 at an acute angle. In one embodiment, theinstaller bevels these bottom edges at about a 45° angle.

For the plurality of sheets 38 that are not designated as corner sheets40 or bottom sheets 44, the installer processes the edges of these sidesheets 42 to remove any uneven surfaces. In one embodiment, theinstaller processes these edges as substantially straight, i.e., in anon-beveled configuration (FIG. 8). In another embodiment, the installerprocesses the edges of these sheets 42 in a beveled configuration (FIG.9). These processes may be shop fabricated.

At the tank site, the installer cleans and prepares surfaces of the tank28 and the backside of the plurality of sheets 38 so that the installercan apply an adhesive cement to both the prepared surfaces of the tank28 and the back sides of the plurality of sheets 38. The installer, aspart of the cleaning process, may swab the surface of the back of theplurality of sheets 38 with methyl ethyl ketone.

The installer then applies an adhesive cement on the prepared surfacesof the tank 28 and the swabbed backsides of the plurality of sheets 38.More than one coat of cement may be applied to the tank surface and thebackside of the plurality of sheets 38. When applying cement with apaint roller the installer uses a short roller in order to preventexcessive cement build up along the tank 28 surface and the backsides ofthe plurality of sheets 38. In the event the plurality of sheets 38cannot be applied to the prepared surface of the tank 28 for an extendedperiod of time and the cement loses its tack, the cement surface shallbe refreshened or re-tacktified by applying another coat of cement.

After the surface of the tank 28 and the back sides of the plurality ofsheets 38 have been properly cemented, the installer bonds the bottomsheet 44 of the plurality of sheets 38 to the bottom 32 of the tank 28.The installer places the bottom sheet 44 against the prepared bottom ofthe tank 28 and bonds the bottom sheet 44 to the bottom of the tank 28by rolling or by pressuring the bottom sheet 44 to the bottom of thetank 28 to avoid trapping air between the bottom sheet 44 and the tank28. The bottom sheet 44 is bonded to the bottom 32 of the tank 28 makingsure the bottom edges are positioned flush against the sidewalls 30 ofthe tank 28. Additionally, the installer presses and rolls the bottomsheet 44 into the corners 36 in such a manner as to prevent bridging. Inrolling out the air during the placement of the bottom sheet 44, theinstaller rolls from the center of the bottom sheet 44 and progressivelyfrom one end to the other to avoid pocketing air.

After bonding the bottom sheet 44, the installer bonds the pair ofsheets 40 of the plurality of sheets 38 to adjacent walls 30 of the tank28 and above the bottom sheet 44 such that the first edges 46 of thepair of sheets 40 are positioned at the intersection of adjacent walls30 (i.e., the tank corner 36) of the tank 28 to position an interface 54(FIG. 7) between the pair of sheets 40. Since the first edges 46 of theadjacent corner sheets may be beveled, the pair of sheets 40 ispositioned at the corner intersection of the adjacent walls 30 toposition a beveled region 56 between the pair of sheets 40 (FIG. 7). Theinstaller then bonds the pair of sheets 40 to the walls 30 of the tank28 by rolling or by pressuring the pair of sheets 40 to the walls 30 ofthe tank 28 to avoid trapping air between the pair of sheets 40 and thewalls 30 of the tank 28. The pair of sheets 40 is bonded to the walls 30of the tank 28 making sure the bottom edges of the pair of sheets 40 arepositioned flush against the bonded bottom sheet 44. The installerpresses and rolls the pair of sheets 44 into the corners in such amanner as to prevent overslipping.

After the corner pairs of sheets 40 and bottom sheet 44 are properlybonded to the tank 28, the installer activates a handle-heldextrusion-welding device 58 (FIG. 10). The welding device 58 consistsessentially of a hand-held drill serving as the drive system andremovable attachment for this drill. In the attachment, a strand ofthermoplastic material 60, supplied via one or several feed channelsfrom a feed device, is first chopped up. The thermoplastic material 60is then heated in a conveying device usually in the form of a wormconveyor and a plastering device so that the chopped thermoplasticmaterial 60 reaches a plastic state and is then expelled as weldingmaterial through a welding chute of the welding device 58. The chuteincludes a degenerating device in the shape of an internal blower aswell as a heating device. In one embodiment, the thermoplastic material60 of the present disclosure comprises: permanent thermoplastic liningmaterials such as, but not limited to, flexible polyvinyl chloride(F-PVC), or polyethylene (HMW, HDPE, or LDPE), or polyurethane/ PVCalloy, or synthetic rubber or flouropolymer (homopolymer or HFPcopolymer PVDF, or alloys), ethylene-chloro-tri-fluoro-ethylene (Halar),or laminations of thermoplastic materials such as above. As such,extrusion welding of the present disclosure comprises heating andforcing out, under constant pressure and temperature, the thermoplasticmaterial 60.

Referring to FIG. 10 and turning to FIGS. 11-13 and FIG. 22, theinstaller extrusion welds the corner pair of sheets 40 together byinfusing the molten thermoplastic material 60 along the pair of sheets40 and within the beveled region 56 of the pair of sheets 40. Infusingthe molten thermoplastic material 60 comprises introducing thethermoplastic material 60 through and/or over and/or into theintersection (i.e., the beveled region 56) of the associated sheets(i.e., the pair of sheets 40). Since the first edges 46 of the adjacentpair of sheets 40 are beveled, this extrusion welding infuses the moltenthermoplastic material 60 within the beveled edges of the pair of sheets40. Due to the uniformity of the beveled edges, the weld infuses withinthe beveled regions 56 to seal the pair of sheets 40 together. Inwelding the pair of sheets 40, the installer typically welds from thetop of the interface 54 between the pair of sheets 40 to the bottom ofthe interface 54. The installer repeats the thermoplastic weldingprocess for the other pair of sheets 40 bonded to the remaining cornersof the tank 28. FIG. 11 illustrates a front view of an infused weld 62that seals the pair of sheets 40 while FIG. 12 illustrates a back viewof the infused weld 62. Additionally, FIG. 13 shows a plan view of theinfused weld 62 for the pair of sheets 40. Turning to FIG. 14, in oneembodiment, the thermoplastic material 60 may weld the beveled region 56between the pair of sheets 40 and slightly infuse beyond the sheets 40to further seal the tank 28. FIG. 14 exaggerates the amount of infusedthermoplastic material 60 beyond the region 54 for purposes of clarity.Since the weld infuses within the sheets 40, the weld 62 also fills anyvoid that exists between the sheets 40 and the tank weld or othercomponents of the tank. Furthermore, should the liner 26 shrink viainteraction of the liner with a particular content such as a chemical,then the infused weld 62 maintains the integrity of liner 26 andmaintains the sealing effect of the liner 26.

Returning to FIG. 10, the installer extrusion welds each corner pair ofsheets 40 to the bottom sheet 44 by infusing the molten thermoplasticmaterial 60 along and in between the pair of sheets 40 and the bottomsheet 44 wherein the infused material seals the pair of sheets 40 to thebottom sheet 44. Infusing the molten thermoplastic material 60 comprisesintroducing the thermoplastic material 60 through and/or over and/orinto the intersection (i.e., the beveled region 56) of the associatedsheets (i.e., the pair of sheets 40). In one embodiment, when the edgesof the bottom sheet 44 and the bottom edges of the pair of sheets 40 arebeveled, the extrusion welding infuses the molten thermoplastic material60 within the beveled region between the pair of sheets 40 and thebottom sheet 44. In another embodiment, when the edges of the bottomsheet 44 and the bottom edges of the pair of sheets 40 are nonbeveled,the extrusion welding infuses the molten thermoplastic material 60within the interface between the pair of sheets 40 and the bottom sheet44. It should be known that the extrusion welding infuses the moltenthermoplastic material 60 for any combination of beveled and non-bevelededges for the pair of sheets 40 and the bottom sheet 44. In welding thepair of sheets 40 to the bottom sheet 44, the installer typically weldsfrom the left to the right. FIG. 10 illustrates the installer extrusionwelding the pair of sheets 40 to the bottom sheet 44.

The extrusion weld 62 reinforces the material of the liner 26 from anyreduction of the physical properties of the liner material that mayoccur during the installation process. The extrusion weld 62 isdifferent from other welds, such as the “cap over” flat strip weld or“cap over” corner strip weld previously discussed. Since the infusion ofthe thermoplastic material 60 is an automated process via the extrusionwelder 58, the thermoplastic material 60 is applied under controlledparameters such as constant pressure and constant temperature over time,which minimizes or eliminates pinholes. The extrusion welder 58 controlsthe melt pressure and the melt temperature with a display and controlbox for convenient operation and monitoring. Because of the controlledpressure and temperature, the extruded thermoplastic material 60 fusesmore material within the sheets 38 than other weld methods. Thisautomatic application of the thermoplastic material 60 under controlledparameters creates a thicker, deeper and stronger extrusion weld 62while minimizing or eliminating pinholes.

Turning to FIG. 15, the present disclosure further comprises an insert.In one embodiment, the insert 64 comprises a triangular shape. Theinstaller may form the insert 64 from the same material as the linermaterial for the lining 26. The thickness of the insert 64 has a rangeof about 3/16 inches to about ⅜ inches. The installer positions theinsert 64 at each liner corner 66 (shown in FIG. 10 for clarity) whichis formed by the infused pair of sheets 40 and bottom sheet 44.Referring to FIG. 16, the installer then extrusion welds the insert 64to the infused pair of sheets 40 and the bottom sheet 44. As shown,extrusion welding the insert 64 to the liner corner 66 comprisesinfusing molten thermoplastic material 60 at predetermined distancebeyond the insert 64 and along the infused pair of sheets 40 and bottomsheet 44. Infusing the molten thermoplastic material 60 comprisesintroducing the thermoplastic material 60 through and/or over and/orinto the intersection (i.e., the beveled region 56) of the associatedsheets (i.e., the pair of sheets 40) and insert 64. This thermoplasticmaterial 60 is also infused under the controlled parameters of constantpressure and constant temperature over time to eliminate pinholes. Thiswelding enhances the strength of the weld 68 between the insert 64 andthe liner corner 66. In one embodiment, the predetermined distancebeyond the insert 64 has a range of about two inches to about fourinches. The installer repeats the welding of inserts 64 to each linercorner 66.

Returning to FIG. 5, the installer then bonds the other sheets 42 of theplurality of sheets 38 to the remaining surfaces of the tank 28. Afterbonding sheets 42 to the remaining surfaces of the tank 28, theinstaller welds contacting edges of any adjacent sheets 42 to anyrespective bonded sheet 38. As shown in FIG. 8, in one embodiment, theinstaller butt-welds the straight edges of adjacent sheets 42. As shownin FIG. 9, in another embodiment, the installer extrusion welds betweenthe beveled edges of adjacent sheets 42. Infusing the moltenthermoplastic material 60 comprises introducing the thermoplasticmaterial 60 through and/or over and/or into the intersection (i.e., thebeveled region 56) of the associated sheets (i.e., the pair of sheets40). In this embodiment, the thermoplastic material 60 is infused underthe controlled parameters of constant pressure and constant temperatureover time to eliminate pinholes. The installer also bonds respectivesheets 42 adjacent to the second edges 48 of each of the corner pair ofsheets 40. In particular, the installer bonds the edges of the othersheets 42 in contact with the second edges 48 of the pair of sheets 40.In this position, the installer may butt-weld the other sheets 42 to theadjacent second edges 46 of the pair of sheets 40. In one embodiment,the installer butt-welds the straight edges 46 of adjacent sheets 40,42. As shown in FIG. 9, in another embodiment, the installer extrusionwelds between the beveled edges of the adjacent sheets 40, 42. In thisembodiment, the thermoplastic material 60 is infused under thecontrolled parameters of the constant pressure and constant temperatureover time to eliminate pinholes. FIG. 5 generally illustrates the weld(butt-weld/infused weld) that bonds corner sheets 40 to side sheets 42.It should be known that multiple side sheets 42 may be bonded and weldedon any particular wall 30 of the tank 10 depending on the size of thetank 10. As the tank 10 may have a substantially tall height, it shouldbe known that ascending rows of corner sheets 40 and side sheets 42 maybe bonded and welded under the previously discussed processes.

Table 1 lists strength test results for a variety of weld locations forthe welds of the present disclosure and prior art welds. The tests wereconducted on an Instron Model 1122 1,000 lb. load cell, wherein allwelds tested were used with Koroseal® liner material. In the table, the“base” refers to the stock material with no welds whatsoever. The“corner extrusion weld” position refers to the welding process of thepresent disclosure for welding the pair of side sheets. The “prior artweld” position refers to current welding processes such as the stripweld process previously discussed. The “butt weld” position refers tothe welding process of the present disclosure as previously discussedand shown in FIG. 8. As shown in Table 1, the welding process of thepresent disclosure results in higher weld strengths than the prior artwelds.

TABLE 1 Failure Weld Material Load - Strength- Weld ThicknessTemperature Lbs./inch Lbs./inch Base 3/32 inch 70° F. 233 245 Corner3/32 inch 70° F. 228 228 Extrusion Weld Prior Art 3/32 inch 70° F. 163165 Weld Base 3/16 inch 70° F. 485 414 Corner 3/16 inch 70° F. 324 317Extrusion Weld Prior Art 3/16 inch 70° F. 306 227 Weld Corner 3/16 inch180° F.  135 98 Extrusion Weld Prior Art 3/16 inch 180° F.  78 54 WeldButt Weld 3/16 inch 70° F. 405 397

Turning to FIG. 17, the resulting lining 26 formed by the process of thepresent disclosure is shown. As illustrated, the lining 26 comprises thebottom sheet 44, the pairs of sheets 40 wherein each pair has the firstedge 46 and the second edge 48 that may be beveled forming the beveledregion 56 between each pair of sheets 40. The lining 26 furthercomprises the infused weld 62 along and within the interface 54 that isbetween the corner sheets 40. The extrusion weld 62 seals the pair ofsheets 40 to each other and to the bottom sheet 44 while eliminatingpinholes. The lining 26 further comprises the insert 64 welded to thelining corner 66 (FIG. 15) that is formed by the pairs of sheets 40 andthe bottom sheet 44. As previously noted the thickness of each sheet 40is at least 3/32 inches. Furthermore, the thickness of the insert 64(FIG. 16) has a range of about 3/16 inches to about ⅜ inches. The lining26 may also comprise the intermediate side sheets 42 (FIG. 5) that maybe welded to the second edge 48 of the pair of each of the sheets 40.

Referring to FIGS. 18-21, some contents such as chrome solutions becomemore reactive as the chrome solution contacts ambient air. PVC isparticularly susceptible to attack by chrome solutions at this solutionand air interface. Accordingly, current process tanks position asacrificial layer of material at the top of the process tank, which isexposed to the ambient air. The reactive solution chemically attacks thesacrificial layer. When the sacrificial layer nears the end of itsuseful life, the installer removes the sacrificial layer and replaces itwith a new sacrificial layer. This replacement process for thesacrificial layer is an expansive and labor intensive process.Currently, sacrificial layers uses a double thickness of bonded HighPerformance Koroseal®, which protects the bonded to metal lining beneathit for a period of time such as one to six years. Other skirt materialssuch as Teflon that are minimally affected or not affected at all by thechrome solution and air interface are very worthy remedies. For example,the previously discussed “drop-in” liner typically uses a Teflon® skirt.

Turning to FIG. 18, in one embodiment, the method of the presentdisclosure comprises bonding an intermediate layer 70 to liner 26. In anembodiment, this intermediate layer 70 comprises a rigid PVC material.Next, the method comprises affixing a sacrificial layer 72 to theintermediate layer 70. In an embodiment, the sacrificial layer 72comprises a polyvinylidene fluoride material commonly known as Kynar™.This sacrificial layer 72 is affixed along the length of theintermediate layer 70 by welding the sacrificial layer 72 to theintermediate layer 70 using a weld material that comprises a hybrid rodmaterial known as JSR #1. FIG. 19 illustrates a resulted liner beingbonded with the intermediate layer 70 and the sacrificial layer 72 beingaffixed to the intermediate layer 70.

Turning to FIG. 20, in another embodiment, the sacrificial layer 72 ofFIG. 18 is directly affixed over the lining 26. In this method, thesesacrificial layers 72 are welded to the lining 26 by using the hybridrod material known as JSR #2 (soft). FIG. 21 illustrates the resultedlining 26 welded to the sacrificial layer 72. In the embodiment of FIGS.18-21, the heights of the intermediate and sacrificial layers 70, 72 maybe adjustable to accommodate varying levels of corrosive solutionsdispersed within the tank.

In an embodiment, the sacrificial layer 72 may be affixed to theintermediate layer 70 or to the lining 26 in a loose or slidingarrangement so that the sacrificial layer 72 can handle thermalexpansion and contraction as the sacrificial layer 72 heats and cools inresponse to chemical reactions.

In another embodiment (not shown), the lining of the present disclosurefurther comprises an absorption layer that bonds to the top of thebottom sheet. In some tank applications, parts that are being processeddamage the bottom sheet due to the part's weight and configuration. Forexample, an operator may mishandle a part while lowering the part in thesolution. As such, the part may rapidly and uncontrollably drop into thetank and tear the bottom sheet. In another example, a part may dislodgefrom its carrier and drop into the tank and tear the bottom sheet.

Some current process tanks are protected by chemical resistant masonrysheathings (“acid brick”). While these brick linings are nothydrostatically tight as a tank lining, (in fact, these linings areporous), the linings do offer both thermal and mechanical protection tothe bottom sheet of the liner. Acid brick has a very high cost factor,however, as it must be installed on site, and must be removed andreplaced, if the tank needs eventual relining. For some applications(hard chrome plating for example), the used brick layer is consideredhazardous waste leading to increased risks for personnel and toincreased disposal costs.

In the alternative embodiment, the lining of the present disclosurecomprises an impact absorbing bumper pad positioned over the bottomsheet. In the present disclosure, this impact protective layer comprisesat least one of a honeycomb, egg-crate or laminate structure. Thesestructures may comprise a non-float (high specific gravity)thermoplastic. This structure may also comprise compressible materialthat absorbs impact from dropped parts. By being made of pieces of asize and weight easily handled by installation personnel, this structureis easily removed from the tank bottom if a lining repair on or near thebottom is ever required.

In view of the above, it will be seen that the several objects of thedisclosure are achieved and other advantageous results are obtained. Asvarious changes could be made in the above constructions withoutdeparting from the scope of the disclosure, it is intended that allmatter contained in the above description or shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

1. A method of lining a tank with a plurality of sheets, the tank havingwalls and a bottom that intersect at a corner of the tank, the methodcomprising: bonding a bottom sheet of the plurality of sheets to thebottom of the tank; bonding a pair of sheets of the plurality of sheetsto adjacent walls of the tank and above the bottom sheet, each sheet ofthe pair of sheets having a first edge and a second edge such that thefirst edges of the pair of sheets are positioned at the intersection ofadjacent walls of the tank to position an interface between the pair ofsheets; extrusion welding the pair of sheets together by infusing amolten thermoplastic material along the pair of sheets and within theinterface of the pair of sheets; and extrusion welding the pair ofsheets to the bottom sheet by infusing the molten thermoplastic materialalong and between the pair of sheets and the bottom sheet wherein theinfused thermoplastic material seals the pair of sheets and bottom sheetto isolate the tank from contents that contact the pair of sheets andbottom sheet.
 2. The method of claim 1 further comprising beveling thefirst edges of the pair of sheets and beveling edges of the bottom sheetprior to bonding the pair of the sheets to the adjacent walls.
 3. Themethod of claim 2 wherein infusing the molten thermoplastic materialwithin the interface comprises infusing the molten thermoplasticmaterial within the beveled side edges of the pair of sheets.
 4. Themethod of claim 1 further comprising positioning an insert at a liningcorner formed by the infused pair of sheets and bottom sheet.
 5. Themethod of claim 4 further comprising extrusion welding the insert to theinfused pair of sheets and bottom sheet.
 6. The method of claim 5wherein extrusion welding the insert to the lining corner comprisesinfusing molten thermoplastic material at a pre-determined distancebeyond the insert and along the infused pair of sheets and bottom sheet.7. The method of claim 6 wherein the thickness of the insert has a rangeof about a 3/16 inch to about a ⅜ inch.
 8. The method of claim 6 whereinthe pre-determined distance beyond the insert has a range of about twoinches to about four inches.
 9. The method of claim 1 further comprisingbonding another sheet to the walls of the tank at a position adjacent toone of the pair of welded sheets, the other sheet being bonded to thetank at and in contact with the second edge of the sheet of the pair ofsheets.
 10. The method of claim 9 further comprising extrusion weldingthe other sheet to the adjacent second edge of the sheet of the pair ofsheets.
 11. The method of claim 1 wherein the infused weld between thepair of sheets comprises a weld strength of about 300 pounds/inch.
 12. Alining produced according to the method of claim
 1. 13. A method oflining a plurality of sheets to a tank, the tank having walls and abottom that intersect at a corner of the tank, the method comprising:beveling side edges of a pair of sheets of the plurality of sheets andbeveling edges of a bottom sheet of the plurality of sheets; bonding thebottom sheet to the bottom of the tank; bonding the pair of sheets toadjacent walls of the tank and above the bottom sheet such that thebeveled edges of the pair of sheets are positioned at the intersectionof the adjacent walls to position a beveled region between the pair ofside sheets; extrusion welding the pair of sheets together by infusing amolten thermoplastic material along and between the beveled regions ofthe pair of side sheets; and extrusion welding the pair of sheets to thebottom sheet by infusing the molten thermoplastic material along andbetween the pair of sheets and the bottom sheet wherein the infusedthermoplastic material seals the pair of sheets and bottom sheet toisolate the tank from contents that contact the pair of sheets andbottom sheet when the tank is filled with the contents.
 14. The methodof claim 13 further comprising positioning an insert at a lining cornerhaving the infused pair of sheets and bottom sheet and extrusion weldingthe insert to the infused pair of sheets and bottom sheet.
 15. Themethod of claim 13 further comprising bonding another sheet to the wallsof the tank at a position adjacent and in contact with at least one ofthe pair of infused sheets and extrusion welding the other sheet to onesheet of the pair of welded sheets.
 16. The method of claim 13 furthercomprising welding an intermediate layer of material to the plurality ofsheets and affixing a layer of polyvinylden fluoride to the intermediatelayer.
 17. For use with a tank having side walls and a bottom, a liningcomprising: a bottom sheet bonded to a bottom of the tank; a pluralityof side sheets, each side sheet having a first edge and a second edge,such that a pair of side sheets of the plurality of sheets are bonded tothe tank walls at a position above the bottom sheet, the pair of sidesheets positioning an interface between each of the side sheets; anextrusion weld infused along and within the interface that is betweenthe side sheets wherein the extrusion weld seals the pair of side sheetsto isolate the tank from contents that are disposed within the tank. 18.The lining of claim 17 further comprising a layer of polyvinylidenfluoride affixed to the plurality of sheets.
 19. The lining of claim 17further comprising another extrusion weld infused between the pair ofside sheets and the bottom sheet.
 20. The lining of claim 17 wherein thefirst edge is a beveled edge, the second edge is a non-beveled edge andthe interface is a beveled region.
 21. The lining of claim 17 furthercomprising an insert welded to a liner corner formed by the pair of sidesheets and the bottom sheet.
 22. The lining of claim 21 wherein thethickness of the insert has a range of about a 3/16 inch to about a ⅜inch.
 23. The lining of claim 17 wherein the thickness of each sidesheet of the plurality of sheets is at least 3/32 inches.
 24. The liningof claim 17 wherein the extrusion weld comprises a thermoplasticmaterial that includes at least one of a flexible polyvinyl chloride, apolyethylene, a polyurethane PVC alloy and a flouropolymer material. 25.The lining of claim 17 further comprising sheets that are butt welded tothe non-beveled edge of the pair of each of the side sheets.
 26. Alining method for use with a tank, comprising: bonding a bottom sheet ofa plurality of sheets to the bottom of the tank; bonding a pair ofsheets of the plurality of sheets to adjacent walls of the tank andabove the bottom sheet, each sheet of the pair of sheets having a firstedge and a second edge such that the first edges of the pair of sheetsare positioned at the intersection of adjacent walls of the tank toposition an interface between the pair of sheets; extrusion welding thepair of sheets together by infusing a molten thermoplastic materialalong the pair of sheets and within the interface of the pair of sheets;and extrusion welding the pair of sheets to the bottom sheet by infusingthe molten thermoplastic material along and between the pair of sheetsand the bottom sheet wherein the infused thermoplastic material sealsthe pair of sheets and bottom sheet to isolate the tank from contentsthat contact the pair of sheets and bottom sheet.
 27. The lining methodof claim 26 further comprising beveling the first edges of the pair ofsheets and beveling edges of the bottom sheet prior to bonding thebottom sheet and the pair of side sheets to the tank.
 28. The liningmethod of claim 27 wherein infusing the molten thermoplastic materialwithin the interface comprises infusing the molten thermoplasticmaterial within the beveled side edges of the pair of sheets.
 29. Thelining method of claim 26 further comprising positioning an insert at alining corner formed by the infused pair of sheets and bottom sheet andextrusion welding the insert to the infused pair of sheets and bottomsheet.